Method of mounting an electrical connector to flexible planar material and apparatus therefor

Abstract

There is described a method of establishing an electrical connection through a flexible planar material. The method involves attaching an intermediate coupling element to the flexible planar material so as to align an aperture defined by the intermediate coupling element with a hole through the flexible planar material, and coupling an electrical connector to the intermediate coupling element so as to permit electrical connection through the flexible planar material. In this way, the intermediate coupling element can be attached to the garment during the garment manufacture process, and subsequently the electrical connector can be coupled to the intermediate coupling element separately from the main garment manufacture.

What is claimed is: 
     
       1. A method of establishing an electrical connection through a flexible planar material, the method comprising:
 attaching an intermediate coupling element to the flexible planar material, the intermediate coupling element defining an aperture; and 
 coupling an electrical connector to the intermediate coupling element so as to permit the electrical connection through the flexible planar material, 
 wherein said attaching comprises: 
 aligning the aperture defined by the intermediate coupling element with a hole through the flexible planar material; and 
 attaching the intermediate coupling element to the flexible planar material by means of a sewing operation. 
 
     
     
       2. A method according to  claim 1 , wherein:
 the intermediate coupling element comprises a flange portion extending around at least a part of the aperture to overlap the flexible planar material; and 
 attaching the intermediate coupling to the flexible planar material comprises passing a needle and thread through the flange portion of the intermediate coupling element. 
 
     
     
       3. A method according to  claim 2 , wherein:
 the flange portion comprises a flexible skirt portion; and 
 attaching the intermediate coupling element to the flexible planar material comprises passing a needle and thread through the flexible skirt portion. 
 
     
     
       4. A method according to  claim 2 , wherein attaching the intermediate coupling element to the flexible planar material comprises passing a needle and thread sequentially through the plurality of holes in the flange portion. 
     
     
       5. A method according to  claim 1 , further comprising mounting a support element to the intermediate coupling element, the support element inhibiting flexing movement of the intermediate coupling element. 
     
     
       6. A method according to  claim 5 , wherein said attaching comprises mounting the support element to the intermediate coupling element with the flexible planar material gripped between the intermediate coupling element and the support element. 
     
     
       7. A method according to  claim 6 , wherein sewing the intermediate coupling element to the flexible planar material comprises passing a needle and thread sequentially through a first plurality of holes in the intermediate coupling element and a second plurality of holes in the support element,
 wherein the first plurality of holes and the second plurality of holes are mutually aligned on opposite sides of the flexible planar material when the support element is mounted to the intermediate coupling element. 
 
     
     
       8. A method according to  claim 1 , wherein attaching the intermediate coupling element to the flexible planar material comprises:
 sewing a support element to the flexible planar material; and 
 mounting the intermediate coupling element to the support element, wherein the support element inhibits flexing movement of the intermediate coupling element. 
 
     
     
       9. A method according to  claim 8 , wherein:
 the support element comprises a flange portion arranged to extend around at least a part of the aperture defined by the intermediate coupling element when the intermediate coupling element is mounted to the support element, such that when the intermediate coupling element is mounted to the support element the flange portion of the support element overlaps the flexible planar material; and 
 sewing the support element to the flexible planar material comprises passing a needle and thread through the flange portion of the support element. 
 
     
     
       10. A method according to  claim 1 , wherein said coupling comprises removably coupling the electrical connector to the intermediate coupling element. 
     
     
       11. A method according to  claim 8 , wherein the intermediate coupling element and the electrical connector comprise a mechanical coupling mechanism allowing removable coupling of the electrical connector and the intermediate coupling element. 
     
     
       12. A method according to  claim 11 , wherein the mechanical coupling mechanism comprises a snap-fit mechanism. 
     
     
       13. A method according to  claim 1 , wherein the electrical connector is a first part of an electrical connection assembly, and
 wherein the method further comprises mating the electrical connector with a second part of the electrical connection assembly. 
 
     
     
       14. A method according to  claim 1 , wherein the flexible planar material is a textile material. 
     
     
       15. A method according to  claim 14 , wherein the textile material forms part of a garment. 
     
     
       16. A method according to  claim 15 , wherein the textile electrical component comprises a wire loom. 
     
     
       17. A method according to  claim 1 , wherein the electrical connector is connected to a textile electrical component. 
     
     
       18. A method according to  claim 1 , wherein the intermediate coupling element has no electrical function. 
     
     
       19. A method of preparing a flexible planar material for mounting an electrical connector thereon, the method comprising attaching an intermediate coupling element to the flexible planar material, the intermediate coupling element defining an aperture and having a coupling mechanism for coupling to the electrical connector, wherein said attaching comprises:
 aligning the aperture defined by the intermediate coupling element with a hole through the flexible planar material; and 
 attaching the intermediate coupling element to the flexible planar material by means of a sewing operation. 
 
     
     
       20. A method according to  claim 19 , wherein the intermediate coupling element has no electrical function.